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Polaris 2009 Sportsman X2 500 EFI, Owner'S Manual, Page: 6 / 148

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Polaris 2009 Sportsman X2 500 EFI Owner'S Manual Download Page 6

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TABLE OF CONTENTS

Introduction  . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4
Safety  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7
Features and Controls . . . . . . . . . . . . . . . . . . .  28
Operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  50
Emission Control Systems . . . . . . . . . . . . . . .  74
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .  75
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . .  126
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . .  129
Polaris Products. . . . . . . . . . . . . . . . . . . . . . .  133
Specifications. . . . . . . . . . . . . . . . . . . . . . . . .  134
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  138
Maintenance Log . . . . . . . . . . . . . . . . . . . . . .  144
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  146

Summary of Contents for 2009 Sportsman X2 500 EFI

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Page 3: ...er s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ...

Page 4: ...r safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is i...

Page 5: ... quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is ex...

Page 6: ...ntroduction 4 Safety 7 Features and Controls 28 Operation 50 Emission Control Systems 74 Maintenance 75 Adjustments 126 Troubleshooting 129 Polaris Products 133 Specifications 134 Warranty 138 Maintenance Log 144 Index 146 ...

Page 7: ...al injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The ...

Page 8: ...ety warnings precautions and operating procedures before operating a Polaris ATV Keep this manual with the ATV Never operate an ATV without proper instruction Take a training course Purchasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCoursesm Contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org for information on enrollment in th...

Page 9: ...ing your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Frame VIN ____________________________________________________________ Engine Serial Number ___________________________________________________ Key Number _________________________________________________...

Page 10: ...s ATV you can take the ATV RiderCoursesm by calling ATV Enrollment Express at 800 887 2887 or by visiting www atvsafety org Purchasers of a used Polaris ATV will be charged for this training A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenan...

Page 11: ...er on approved models should wear a hel met that includes a rigid chin guard Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and se...

Page 12: ...o protect arms and legs Riding pants with kneepads and a jersey with shoulder pads provide the best protection Equipment Modifications We strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes The warranty on your Polaris ATV is terminated if any equipment ...

Page 13: ...ent types of terrain Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle See page 7 Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16...

Page 14: ...hange clothing Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas Failure to Inspect Before Oper...

Page 15: ...t carry a passenger until you have at least two hours of driving experience with this vehicle Carrying More Than One Passenger Carrying more than one passenger greatly reduces the operator s ability to balance and control the ATV which may result in an accident or overturn Never carry more than one passenger on this 2 up ATV Using Alcohol or Drugs Operating the ATV after consuming alcohol or drugs...

Page 16: ...n Avoid operating the ATV on pavement ATV tires are designed for off road use If it s unavoidable travel slowly and avoid sudden turns or stops Operating on Public Roads Operating this ATV on public streets roads or highways could result in a collision with another vehicle Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s unlawful to ope...

Page 17: ...r should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times The passenger should never hold on to the operator Turning Improperly Turning improperly could cause loss of traction loss of control accident or overturn Always follow proper procedures for turning as described in the owner s manual Practice turning at slow spe...

Page 18: ...edures for traveling down hills as described in the owner s manual See page 63 Never operate with the differential unlocked while operating on a hill or other irregular terrain Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See pages 29 and 39 Crossing Hillsides Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid cr...

Page 19: ...e ATV around and remount following the procedure described in the owner s manual See page 64 If the ATV begins rolling backwards Keep operator and passenger body weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the foot brake as well and then lock the parking brake Dismount on the uphill side o...

Page 20: ...in Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions Operating Improperly in Reverse Improperly operating in reverse cou...

Page 21: ...bstacles could cause loss of control or overturn Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees If unavoidable use extreme caution and always follow proper operating procedures as outlined in this manual See page 67 Skidding or Sliding Skidding or sliding can cause loss of control or overturn if tires regain traction unexpecte...

Page 22: ... brakes may have reduced stopping ability After leaving water test the brakes Apply them lightly several times while driving The friction will help dry out the pads Improper Cargo Loading Overloading the ATV or carrying towing cargo improperly may cause changes in handling which could cause loss of control or an accident Never exceed the stated load capacity for this ATV Cargo should be properly d...

Page 23: ...f water Poor Visibility Operating the ATV in darkness or inclement weather could result in a collision or accident especially if operating on a road or street This ATV is not equipped with highway approved lights Operate this vehicle off road only Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Clean headlights frequently and replace burned...

Page 24: ... increased risk of overturn and loss of control Never secure a passenger to the vehicle or to the operator with a belt rope or similar device Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when ...

Page 25: ...the vehicle If an informational or graphic label becomes illegible or comes off con tact your Polaris dealer to purchase a replacement Replacement safety labels are provided by Polaris at no charge The part number is printed on the label Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases the chances of severe injury or death to both operator and passenger NEVER oper...

Page 26: ... OPERATOR MUST ALWAYS use proper riding techniques to avoid overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control reduce speed and use extra caution at all times when carrying a passenger dismount passenger when conditions require make sure passenger reads and understands this label and passenger safety label LOCATE AND READ OPERA...

Page 27: ... OR ALCOHOL NEVER carry a passenger too small to firmly plant feet on footrests and securely grasp hand holds THE PASSENGER MUST ALWAYS use an approved helmet and protective gear securely grasp hand holds and plant feet firmly on footrests while seated in the passenger seat tell operator to slow down or stop if uncomfortable get off and walk if conditions require 7175379 Passenger Safety Warning ...

Page 28: ...g WARNING Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death Cold tire pressure Front 5 0 psi 34 5 kPa Rear 5 0 psi 34 5 kPa Maximum weight capacity 705 lbs 320 kg 7175441 Tire Pressure Load Warning ...

Page 29: ...bined Front Rack and Container Load 90 lbs 41 kg 7174201 Clutch Cover Warning WARNING NO STEP Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death 7172563 Clutch Cover Warning Rack Warning B...

Page 30: ...ngaged Always apply throttle gradually while in reverse CAUTION Do not push switch to engage 4x4 AWD if the rear wheels are spinning This may cause severe drive shaft and clutch damage 7175512 Box Warning WARNING Remove flammable material containers from box before filling WARNING Passengers can be thrown off This can cause serious injury or death Never carry passengers in cargo box Maximum Box Lo...

Page 31: ... is on This switch is also used to toggle through the modes of the rider information center See page 42 Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engine quickly The engine will not start or run when the switch is off Both the main switch and the engine stop switch will shut off all electri cal power to the vehicle including lights Main Key Switch ...

Page 32: ...or death One rear wheel may slip and lose traction or may lift up and grab when it touches the ground again DO NOT operate with the differential unlocked when climbing or descending hills when sidehilling or when operating on uneven loose or slippery terrain such as sand gravel ice snow obstacles and water crossings Place the differential switch in the locked position and operate in ADC 4X4 or 4X4...

Page 33: ...ctronic throttle control could result in failure to perform as designed which could result in an accident Do not attempt to modify the throttle control system or replace it with any after market throttle mechanisms Always ensure that the throttle cable is properly installed to the throttle control Engine speed and vehicle movement are controlled by pressing the throttle lever The throttle lever is...

Page 34: ...e the brake lever toward the handlebar to apply the front and rear brakes These brakes are hydraulically activated disc type brakes that are activated by only one lever Always test brake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected be...

Page 35: ... lead to early brake fade and the possibility of brake failure which could result in an accident After opening a bottle of brake fluid always discard any unused portion Check the brake fluid in the master cylinder before each ride 1 Position the ATV on a level surface 2 Position the handlebars so the master cylinder is level 3 View the brake fluid level through the indicator window on the top of t...

Page 36: ... unlocked position WARNING Operating the ATV while the parking brake is engaged could result in an accident or fire Always check to be sure the parking brake is disengaged before operating The parking brake may relax if left on for a long period of time Always block the wheels to prevent rolling Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option i...

Page 37: ...e used as a backup for the main brake system Should the main system fail use the auxiliary foot brake Since this is a rear brake only it will not be as effective as the all wheel single lever system The auxiliary foot brake is located on the inside of the right footrest Operate this brake with your right foot If the rear wheels slide while using the auxiliary brake reduce brake pedal pressure to b...

Page 38: ...ne is idling move the lever to the desired gear NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Whenever the ATV is left unattended always place the transmission in PARK and lock the parking brake Belt Life To extend belt life use low forward gear in heavy pulling situations and when operating at less than seven miles per hour f...

Page 39: ...replace the filter after every 200 hours of operation and any time the fuel becomes contaminated with dirt or debris Do not attempt to clean the fuel filter Fuel Tank Cap Remove the fuel tank cap to add fuel to the fuel tank Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use E 85 fuel Fuel Tank Cap ...

Page 40: ...hen the switch is on 4X4 the ATV is in 4X4 and the 4X4 indicator light in the instrument cluster will be on When in 4X4 the demand drive unit will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the demand drive unit will automatically disengage There is no limit to the length of time the vehicle may remain in 4X4 Tip The override switch allows acti...

Page 41: ...If the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the 4X4 switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to 4X4 NOTICE Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may cause severe drive shaft and gea...

Page 42: ...follow ing conditions occur The 4X4 switch must be in the ADC 4X4 position Vehicle speed must be 15 mph 24 km h or less The throttle must be closed throttle lever released The transmission must be in gear high low or reverse Disengaging Active Descent Control The ADC system will automatically disengage if at least one of the fol lowing conditions occur The 4X4 switch is moved out of the ADC 4X4 po...

Page 43: ...he 1 up position for single rider operation Never carry cargo in the rear box when operating the ATV in the 2 up mode with a passenger Seat Conversion 1 Make sure the cargo box dump lever is securely latched 2 Rotate both operator backrest latches 1 4 turn to release the locks 3 Tilt the backrest slightly forward 4 Pull the passenger backrest upward from the bed of the cargo box Dump Lever Passeng...

Page 44: ...tions 6 Lower the operator backrest to create the passenger seat Two retaining pins under the seat should fit into the two grommets on the seat base 7 Test the passenger seat lock out by attempting to release the cargo box dump lever If the dump lever releases the seat is not secure Repeat the set up procedure If the lock out is not working properly do not allow a passenger to ride the vehicle See...

Page 45: ...iter function that limits the ATV s speed to approximately 7 9 mph Refer to page 28 for additional information NOTICE High water pressure may damage ATV components Wash the ATV by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the speedometer lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Do not ...

Page 46: ...de Indicator 5 Low Battery and Over Voltage This warning usually indicates that the ATV is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high elec trical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning 6 Odometer Tachometer Tripmeter Hour Meter Clock 7 Fuel Gauge The segment...

Page 47: ...s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 In the Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation Tachometer Mode The engine RPM is disp...

Page 48: ...n as the display is activated 5 Use the mode button to toggle through the diagnostic screens Clock Screen To reset the clock 1 Enter the diagnostic mode 2 Toggle to the clock screen 3 Press and hold the mode button until the hour display flashes Release the button 4 Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly...

Page 49: ... for all major repairs Gear Circuit Diagnostic Screen This screen displays the resistance value in ohms being read at the gear switch input of the gauge This screen is for informational purposes only Please see your dealer for all major repairs Programmable service interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds eac...

Page 50: ...e button 4 Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly 5 If you scroll past the intended number press and hold the button until the hours cycle back to zero 6 When the desired setting is displayed wait until the wrench icon stops flashing The new service interval is now programmed Miles Kilometers toggle The ...

Page 51: ...4 Count the number of times the Check Engine icon flashes Example For the two blink codes 42 and 36 the Check Engine icon will flash 4 times pause then flash 2 times code 42 then pause longer blink 3 times pause and blink 6 times code 36 5 A code 61 will signal the end of the sequence If no blink codes are found only codes 12 and 61 will appear during the sequence Tip The word WAIt will remain on ...

Page 52: ... Sensor Low 46 Barometric Pressure Manifold Air Pressure Sensor High 47 IAC Stepper Motor Open Load 47 IAC Stepper Motor Short to Ground 51 Injector Circuit Malfunction Cyl 1 Open Load Short to Ground 51 Injector Circuit Malfunction Cyl 1 Shorted Load Short to Battery 52 Injector Circuit Malfunction Cyl 2 Open Load Short to Ground 52 Injector Circuit Malfunction Cyl 2 Shorted Load Short to Battery...

Page 53: ...s of operation or the time it takes to use the first two full tanks of gasoline No single action on your part is as important as following the proce dures for a proper break in Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components NOTICE Excessive heat build up during the first three hours of operation will damage clos...

Page 54: ...ry the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 52 6 Pull only light loads 7 Change both the oil and the filter at 20 hours or one month which ever comes first PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and be...

Page 55: ...pect condition and pressure 97 Wheels fasteners Inspect ensure fastener tightness 97 98 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 36 80 Coolant level if applicable Ensure proper level 92 93 Coolant hoses if applicable Inspect for leaks Throttle Ensure proper operation 30 128 Indicator lights switches Ensure operation 28 Engine stop switch Ensure proper o...

Page 56: ...n and darkness Clean headlights fre quently and replace burned out headlamps promptly 7 Drive in a manner appropriate for your skills your passenger s skills and operating conditions Never operate at excessive speeds Never attempt wheelies jumps or other stunts Never remove your hands from the handlebars while operating and always keep both feet on the footrests 8 Never consume alcohol or drugs be...

Page 57: ...hicle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect for the terrain avoid littering and always stay on the designated trails Trail Etiquette Always practice good etiquette when riding Allow a safe distance between your vehicle and other vehicles operating in the same area Communicate to onc...

Page 58: ...0 seconds before engaging the starter again 6 If the engine does not start return the key to the OFF position and wait five seconds before attempting to start again Activate the starter for another five seconds if necessary Repeat this procedure until the engine starts NOTICE Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes ...

Page 59: ... side 6 Sit upright with both feet on the footrests and both hands on the handlebars 7 Start the engine and allow it to warm up 8 Shift the transmission into gear 9 Check your surroundings and determine your path of travel 10 Release the parking brake 11 Slowly depress the throttle with your right thumb and begin driving 12 Drive slowly Practice maneuvering and using the throttle and brakes on lev...

Page 60: ...cargo 3 Steer in the direction of the turn 4 Keep both feet on the footrests 5 Lean your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse 6 Practice making turns at slow speeds before atte...

Page 61: ...the pre ride inspection See page 52 5 Convert the seat for 2 up riding See page 40 Always make sure the passenger seat lock out is functioning properly before carrying a passenger 6 Lock the parking brake 7 Mount the vehicle from the left side After the operator is seated the passenger should mount the vehicle from the left side Always make sure the brake is engaged to ensure the vehicle remains m...

Page 62: ...s and both hands on the passenger grab handles at all times The passenger should never hold on to the operator Never secure a passenger to the vehicle or to the operator with a belt rope or similar device 14 Make sure the passenger understands the importance of active riding When hill climbing or performing maneuvers a passenger should shift body weight in the same manner in which the driver shift...

Page 63: ... traction NOTICE Severe damage to drive train may occur if the 4X4 is engaged while the wheels are spinning Allow the rear wheels to stop spinning before engaging 4X4 or engage 4X4 before wheels begin to lose traction 4 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 5 Never apply the brakes during a skid Correct a skid by turning the handl...

Page 64: ...id steep hills 15 maximum 5 Always check the terrain carefully before ascending any hill 6 Never climb hills with excessively slippery or loose surfaces 7 Keep both feet on the footrests 8 Shift body weight uphill A passenger should also shift body weight uphill 9 Proceed at a steady rate of speed and throttle opening Opening the throttle suddenly could cause the ATV to flip over backwards 10 Neve...

Page 65: ...n 2 Avoid crossing the side of a steep hill 3 If operating in 2X4 mode make sure the differential is locked 4 Do not cross a hillside with a passenger on board Ask the passenger to dismount and walk across the hillside before remounting the vehicle 5 Lean into the hill transferring your upper body weight toward the hill while keeping your feet on the footrests 6 If the vehicle begins to tip quickl...

Page 66: ... forward gear Do not descend a hill with the transmission in neutral 4 Slow down Never travel down a hill at high speed 5 Drive straight downhill Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side 6 Shift body weight uphill A passenger should also shift body weight uphill 7 Apply the brakes slightly to aid in slowing Applying the brakes too firmly may...

Page 67: ...64 OPERATION Turning Around on a Hill K Turn If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around 8 ft 2 4 m ...

Page 68: ...cle is pointing straight uphill A passen ger should not remount until the vehicle returns to firm level ground 5 Staying uphill of the vehicle turn the handlebars full left 6 While holding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your right until it s point ing across the hill or slightly downward 7 Lock the parking brake Remount the vehicle fro...

Page 69: ...uid and all grease fittings If the vehicle tips or overturns in water or if the engine stops during or after operating in water restarting can result in serious engine damage Transport the vehicle to your dealer for service before restarting the engine If this is not possible follow the vehicle immersion inspection and drying procedures outlined on page 108 then see your dealer for service at the ...

Page 70: ...constantly alert for haz ards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Never attempt to operate over large obstacles such as rocks or fallen trees 5 Always have a passenger dismount before operating over an obsta cle that could cause a fall from the vehicle or vehicle tipover ...

Page 71: ... turning at sharp angles 6 Never open the throttle suddenly 7 Do not use the override switch unless additional wheel speed is required for vehicle movement Use the override with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Operate the throttle just enough to maintain a desired speed NOTICE Excessive throttle operation while in the speed limit mode may...

Page 72: ... an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Always block the rear wheels on the downhill side ...

Page 73: ...hat cannot be centered secure the load and operate with extra caution SECURE ALL LOADS BEFORE OPERATING Unsecured loads may shift and create unstable operating conditions which could result in loss of control of the vehicle Always be sure that the cargo bed is lowered and latched before moving the vehicle USE EXTREME CAUTION when operating with loads extending beyond the rack or cargo bed Stabilit...

Page 74: ...ys load the cargo box with the load as far forward as possible 2 Do not obstruct the headlight beam with cargo 3 Use low forward gear when hauling or towing heavy cargo to extend belt life 4 Always operate the vehicle with extreme caution whenever hauling or towing loads Balance handling and control may be affected 5 Slow down 6 Make sure the cargo box dump latch is securely latched before load in...

Page 75: ...ght capacity of the vehicle NOTICE Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your ATV warranty Never install a hitch longer than 4 10 cm Never install automotive accessories on your Polaris ATV Always install Polaris approved or equivalent accessories designed for ATV use Maximum Towing Capacities Do not exceed...

Page 76: ...tion the weight as far forward and as low as possible 6 Pull the cargo box release lever upward 7 Lift the front of the cargo box and dump the cargo 8 Lower the cargo box and make sure the release latch is secured 9 Secure the tailgate WARNING Operating with the cargo box in the raised position can cause serious injury and damage to the vehicle The cargo box could close unexpectedly and injure the...

Page 77: ...343 1 c Violations are subject to monetary penalties Fed eral regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust emissions are controlle...

Page 78: ...rvice and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high R...

Page 79: ... is reached first Item Maintenance Interval whichever comes first Remarks Hours Calendar Miles Km Steering Pre Ride Make adjustments as needed See Pre Ride Checklist on page 52 Front suspension Pre Ride Rear suspension Pre Ride Tires Pre Ride Brake fluid level Pre Ride Brake lever travel Pre Ride Brake system Pre Ride Passenger seat lock out Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre R...

Page 80: ...nspect clean if needed X General lubrication 50 H 3 M 500 800 Lubricate all fittings pivots cables etc Shift linkage 50 H 6 M 500 800 Inspect lubricate Q Steering 50 H 6 M 500 800 Lubricate X Front suspension 50 H 6 M 500 800 Lubricate X Rear suspension 50 H 6 M 500 800 Lubricate Q E Throttle Cable ETC Switch 50 H 6 M 500 800 Inspect adjust lubricate replace if necessary E Throttle Body Intake Duc...

Page 81: ... H 12 M 1000 1600 Inspect Exhaust muffler pipe 100 H 12 M 1000 1600 Inspect Q E Spark plug 100 H 12 M 1000 1600 Inspect replace as needed X Wiring 100 H 12 M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc Q Clutches drive and driven 100 H 12 M 1000 1600 Inspect clean replace worn parts Q Front wheel bearings 100 H 12 M 1000 1600 Inspect...

Page 82: ...provided for additional lubrication at the user s discretion Item Lube Capacity at Fluid Change Inspection Procedure Engine Oil PS 4 PLUS Performance Synthetic 2W 50 2 qt 1 9 l See page 80 Brake Fluid DOT 4 Only See page 32 Transmission Oil Polaris AGL Syn thetic Gearcase Lube 32 oz 948 ml See page 88 Demand Drive Fluid Front Gearcase Demand Drive LT Premium Fluid 9 3 oz 275 ml See page 89 ADC Flu...

Page 83: ...ge 79 Oil may need to be changed more frequently if Polaris oil is not used Always use 2W 50 oil Follow the manufacturer s recommendations for ambient temperature operation See page 133 for the part numbers of Polaris products NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands ...

Page 84: ...nkcase If the oil level is over the full safe mark change the oil immediately 1 Position the vehicle on a level surface 2 Start the engine Allow it to idle for 20 30 seconds Stop the engine 3 Remove the dipstick Wipe it dry with a clean cloth 4 Reinstall the dipstick completely 5 Remove the dipstick and check the oil level Maintain the oil level in the safe range Do not overfill 6 Reinstall the di...

Page 85: ...The dipstick must be inserted com pletely to keep the angle and depth of the stick consistent 4 Remove the dipstick and check the oil level Maintain the oil level in the safe range Do not overfill Tip Due to the dipstick entry angle into the crankcase the oil level will read higher on the bottom side of the dipstick Always read the level on the upper surface of the dip stick 5 After reinstalling t...

Page 86: ...the drain plug The sealing sur faces on drain plug and crank case should be clean and free of burrs nicks or scratches 8 Reinstall the drain plug Torque to 14 17 ft lbs 19 23 Nm 9 Disconnect the lower oil deliv ery hose and remove the screen fitting from the oil tank Clean the fitting Tip The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal tape 10 Reinstall the screen fitting and ...

Page 87: ...t an additional 1 2 turn 16 Approximately one cup of engine oil will remain in the crankcase To drain remove the drain plug on the lower right side of the crank case 17 Reinstall the drain plug The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 18 Torque to 14 ft lbs 19 Nm 19 Remove the dipstick 20 Add two quarts 1 9 l of recommended oil If th...

Page 88: ...ximately 2 5 cm from the oil tank between the end of the oil tank vent fitting and the vent line s pressure relief slit 2 Start the engine Allow it to idle for 10 20 seconds 3 Remove the vent line clamp If the line is bled properly you should hear a rush of air indicating that the line is properly primed and ready for operation Tip If you do not hear air the line has not bled Repeat the priming pr...

Page 89: ...up at idle for two to three min utes 3 Stop the engine 4 Clean the area around the drain plug 5 Place a drain pan under the crankcase 6 Remove the drain plug Allow the oil to drain completely CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 7 Install a new sealing washer on the drain plug The sealing surfaces on drain plug and crankcase should be clean and free of burrs...

Page 90: ...l Check to make sure the o ring is in good condition 12 Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface then turn it an additional 1 2 turn 13 Remove the dipstick 14 Add two quarts 1 9 l of recommended oil 15 Place the transmission in PARK 16 Lock the parking brake 17 Start the engine Allow it to idle for one to two minutes 18 Stop the en...

Page 91: ...cant See page 133 for the part numbers of Polaris products The fill plug is located on the left side of the ATV under the rear fender behind the wheel The drain plug is located on the right side of the gearcase on the right side of the ATV behind the wheel well Transmission Oil Level 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Check the oil level Add the recommended oil as n...

Page 92: ... Always check and change the demand drive fluid at the intervals out lined in the Periodic Maintenance Chart beginning on page 75 We rec ommend the use of Demand Drive LT Premium Fluid Use of other fluids may result in improper operation of components See page 133 for the part numbers of Polaris products Maintain the fluid level at the bottom of the fill hole threads See below for capacity The fil...

Page 93: ...commended fluid See page 89 for capacity Maintain the fluid level at the bottom of the fill hole threads 7 Reinstall the fill plug Torque to 8 10 ft lbs 11 14 Nm 8 Check for leaks 9 Dispose of used fluid properly Active Descent Control ADC Fluid Two fluid levels must be maintained on your vehicle the demand drive fluid and the ADC fluid See page 89 for demand drive fluid mainte nance Check and cha...

Page 94: ...quate bleeding and reduced performance of the system 4 Fill the reservoir to the maximum line with fresh ADC fluid 5 Remove the protective caps from the bleeder valves 6 Slowly loosen one of the valves turn counter clockwise and allow fluid and trapped air to flow from the fitting Close the valve when clean fluid begins to flow Repeat this step for the remaining valve IMPORTANT Close the bleeder v...

Page 95: ... is purging itself of trapped air Check the coolant level and maintain as recommended by adding coolant to the recovery bottle Polaris recommends the use of Polaris Premium 60 40 anti freeze cool ant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water See page 133 for the ...

Page 96: ...he radiator Add coolant as needed CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 Open the front box cover and pull open the access door 2 Remove the pressure cap 3 Using a funnel slowly add coolant through the radiator filler neck 4 Reinstall the pressure cap Use of a non standa...

Page 97: ...or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill The following checks are recommended to keep the brake system in good operating condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 32 2 Check the brake system for fluid leaks 3 Check the brakes...

Page 98: ...d position 3 Tie a length of string between two stands as shown in the illustration Position the stands so that the string is flush with the side of the rear tire If available you may use a long straight edge instead of string 4 Measure the distance from the string to the rim at the front 1 and rear 2 of the front rim The rear measurement should be 1 16 1 8 2 3 mm more than the front measurement o...

Page 99: ...side panel near the rear cab With a firm motion pull the panel outward to disengage the side panel from the grommet Pull the panel downward and rearward to remove it 3 When reinstalling side panels align the fasteners and press firmly to secure them Footwell Removal 1 Remove the six screws on the bottom of the footwell 2 Use a flat screwdriver or sidecutters to remove the plastic rivets securing t...

Page 100: ...om mended tire type size and pressure Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com ponent operations All service must be performed by your authorized Polaris dealer Wheel Removal 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Loose...

Page 101: ...r the vehicle to the ground 6 Torque the wheel nuts to specification WARNING Loose nuts could cause a tire to come off during operation which could result in an accident or overturn Always ensure that all nuts are torqued to specification Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loos ened for service Nut Type Nut Torque Lug Nut 90 ft lbs 122 Nm...

Page 102: ...c type pre filter from the main filter Wash the pre filter in soapy water then rinse and let dry 5 Reinstall the pre filter over the main filter Install a new main fil ter if needed 6 Reinstall the filter into the air box and tighten the clamp Do not over tighten the clamp as filter damage could occur 7 Reinstall the air box cover and the seat Main Filter Pre Filter ...

Page 103: ...Blow gently through the filter in the direction of the arrow to check for clogging Replace a damaged or clogged filter 4 Check the hoses for cracks deterioration abrasion or leaks Replace as needed 5 Reinstall the filter and hose clamps Tip The filter is effective with the arrow pointing in either direction NOTICE Operation of your vehicle without a breather filter can cause engine damage Always r...

Page 104: ...eed replacement Spare fuses are provided in a compartment on the top of the access door 1 Open the front box cover and pull open the access door 2 Remove the suspect fuse from the fuse panel If the fuse is blown install a new fuse with the same amperage 3 Secure the access door 4 Secure the box cover Fuse Panel Fuses 5or6 15 20 20 ...

Page 105: ...do touch a lamp clean it with denatured alcohol 1 Remove the two screws on the lower front corners of the headlight pod 2 Remove the screw from the rear of the pod 3 Lift the pod slightly while depressing the tabs at the rear of the pod 4 Lift the pod cover and disconnect the speedometer harnesses from the speedometer CAUTION Hot components can cause burns to skin Allow lamps to cool before servic...

Page 106: ...Turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 cm below the mark on the wall Include rider weight on the seat when measuring 5 The adjustment knob is located on the right side of the headlight pod Adjust the beam to the desired position by turning the knob either clockwise or counterclockwise Low Bea...

Page 107: ...ring harness 5 Use a small screwdriver to remove the o rings from the headlight mounting tabs 6 Pull the headlight housing up to release it from the locking tabs 7 Lift the adjusting knob up to remove it from the locking tabs 8 Carefully pull the assembly up and out of the pod 9 Reverse the steps to install the new housing and reassemble the pod The distance from the headlamp parting line to the e...

Page 108: ...adlamp Taillight Brakelight Worklight if equipped Lamp Replacement 1 Open the tailgate 2 Remove the two screws near the tailgate latch 3 Grasp the entire taillight assembly and pull it away from the vehicle 4 Remove the harness connector from the back of the light assem bly 5 Turn the lamp counterclockwise to remove it 6 Apply dielectric grease to the socket and install the new lamp 7 Reinstall th...

Page 109: ...on after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color See page 107 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Rotate the spark plug cap 1 4 turn and pull it off the spark plug 2 Using the special wrench provided in the tool pouch rotat...

Page 110: ...ngine and the service The tip should not be flaky and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect fuel Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of no...

Page 111: ... to water below the footrests 2 Check the air box If water is present dry the air box and replace the filter with a new filter 3 Remove the spark plug 4 Turn the engine over several times using the electric start 5 Dry the spark plug Reinstall the plug or install a new plug 6 Attempt to start the engine If necessary repeat the drying proce dure 7 Take the ATV to your dealer for service as soon as ...

Page 112: ...m the exhaust pipe muffler 1 Remove the arrestor clean out plug from the bottom of the muffler 2 Place the transmission in PARK 3 Start the engine 4 Quickly squeeze and release the throttle lever several times to purge carbon from the system 5 If carbon comes out of the exhaust cover or plug the exhaust outlet Wear protective gloves 6 Lightly tap on the exhaust pipe with a rubber mallet while repe...

Page 113: ...loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manu...

Page 114: ...ue to the system s dependence on engine speed For example when operating at a ground speed of 3 MPH 5 km h in low range the engine speed would be around 3000 RPM This is well above the engagement speed of 1200 1400 RPM However in high range at 3 MPH 5 km h the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be running at a speed too low...

Page 115: ...PARK 4 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 5 Allow the engine RPM to settle to idle speed then shift the trans mission to the lowest available range 6 Test for belt slippage If the belt slips repeat the process 7 Take the vehicle to your dealer for service as soon as possible Co...

Page 116: ...roduce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your ATV may have either a sealed battery which requires little mainte nance or a conventional battery A sealed battery can be identified by its flat covers on the top of the battery A conventional battery ha...

Page 117: ...isconnect the black negative battery cable first 5 Disconnect the red positive battery cable last 6 Lift the battery out of the ATV Be careful not to tip a conventional battery sideways which could spill electrolyte NOTICE If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle ...

Page 118: ...curely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte WARNING Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended 4 On conventional batteries coat the terminals with dielectri...

Page 119: ...ining battery charge by using a Polaris Bat tery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 133 for the part numbers of Polaris products Battery Fluid Conventional Battery A poorly maintained b...

Page 120: ...he sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop ...

Page 121: ...andard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months 3 6 hours 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At l...

Page 122: ...s to contact the vehicle The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not ...

Page 123: ...tact your Polaris dealer for free replacement Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle Follow the instructions on the container Polishing...

Page 124: ... Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the produ...

Page 125: ... or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the entire fuel delivery system Oil and Filter Change the oil and filter See page...

Page 126: ...top the engine 2 Remove the spark plug and add 2 3 tablespoons of engine oil To access the plug hole use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil Do this carefully If you miss the plug hole oil will drain from the spark plug cavity into the hole at the front of the cylinder head and appear to be an oil leak 3 Reinstall the spark plug...

Page 127: ... slightly off the ground Be sure the storage area is well ventilated Cover the vehicle with a genuine Polaris cover Do not use plastic or coated mate rials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation Accessories Auxiliary power outlets provide 12 volt power for operating accesso ries Accessory outlets are available for all models Polaris als...

Page 128: ...Lock the parking brake 4 Always secure the seat in the 1 up position to prevent loss during transporting 5 Secure the fuel cap and oil cap 6 Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets 7 Remove the key to prevent loss during transporting ...

Page 129: ...ster are non adjust able Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension Tip Accessory springs are available through your Polaris dealer Adjuster ...

Page 130: ... or death Follow the adjustment procedures exactly or see your Polaris dealer for service 1 Remove the upper headlight pod 2 Loosen the four handlebar bolts 3 Adjust the handlebar to the desired height Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right 4 Torque the front two bolts to 10 12 ft lbs 14 17 Nm then torque the rear ...

Page 131: ...the handlebar 2 Squeeze the end of the rub ber boot and slide it far enough to expose the end of the inline cable adjuster 3 Loosen the adjuster lock nut 4 Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the thumb lever While adjusting freeplay be sure to flip the throttle lever back and forth 5 Tighten the lock nut 6 Squeeze the end of the rub ber boot a...

Page 132: ... Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of contro...

Page 133: ...Fouled or defective spark plug s Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is on Water or fuel in crankcase Immediately see your Polaris dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plug s Incorrect spark plug g...

Page 134: ...Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Possible Lean Fuel Cause Solution Low or contaminated fuel Add or change fuel clean the fuel system Ki...

Page 135: ...nnections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Overheated engine Clean radiator screen and core clean engine exterior see your...

Page 136: ...l Jug 2876251 Demand Drive LT Premium Fluid 8 oz 237 ml Coolant 2871323 60 40 Coolant gal 3 8 l 2871534 60 40 Coolant qt 95 l Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 3 oz 89 ml cartridge 2871423 Premium All Season Grease 14 oz 414 ml cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 oz 89 ml cartridge 2871551 Pre...

Page 137: ... 48 in 122 cm Wheelbase 57 in 145 cm Ground Clearance 11 in 28 cm Minimum Turning Radius 82 in 208 cm unloaded Fuel Capacity 6 gal 22 7 l Engine Oil Capacity 2 qts 1 9 l Coolant Capacity 2 7 qts 2 5 l Demand Drive Fluid Capacity 9 3 oz 275 ml Transmission Oil Capacity 32 oz 948 ml Engine EH50PLE Displacement 499 cc Bore x Stroke 92 x 75 Alternator Output 350 w Compression Ratio 10 2 1 Fuel System ...

Page 138: ...ront Single Control Hydraulic Disc Brakes Rear Single Control Hydraulic Disc Brake Auxiliary Foot Activated Hydraulic Disc Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 37 5 watt Taillights 8 26 watts Brake Light 26 9 watts Instrument Cluster LCD Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Meters Feet 0 1800...

Page 139: ...n 122 cm Wheelbase 57 in 145 cm Ground Clearance 11 in 28 cm Minimum Turning Radius 82 in 208 cm unloaded Fuel Capacity 6 gal 22 7 l Engine Oil Capacity 2 qts 1 9 l Coolant Capacity 3 4 qts 3 2 l Demand Drive Fluid Capacity 9 3 oz 275 ml Transmission Oil Capacity 32 oz 948 ml Engine EH0760LE Displacement 760 cc Bore x Stroke 80x76 Alternator Output 500 Watts 3000 RPM Compression Ratio 10 1 Fuel Sy...

Page 140: ...11 12 5 psi Brakes Front Single Control Hydraulic Disc Brakes Rear Single Control Hydraulic Disc Brake Auxiliary Foot Activated Hydraulic Disc Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 37 5 watt Taillights 8 26 watts Brake Light 26 9 watts Instrument Cluster LCD Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Heli...

Page 141: ...olaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed...

Page 142: ...rosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or com ponents or products THE ...

Page 143: ...e your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the a...

Page 144: ...eling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show...

Page 145: ...red outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions c...

Page 146: ... replacement of any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT ...

Page 147: ... section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 148: ...145 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

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